Mailing product and method

ABSTRACT

A light-weight mailing product is provided, including first and second walls parallel to each other, each wall having first, second, third and fourth edges, and a third wall attached along the first edges of the first and second walls connecting the first wall to the second wall. The product also includes first and second wall flaps, the first wall flap attached along the second edge of the first wall and the second wall flap attached along the second edge of the second wall, the first wall flap substantially overlapping the second wall flap with the first and second wall flaps parallel to the third wall, and the first and second wall flaps attached together with an adhesive. The product further includes first and second reinforcing flaps, the first reinforcing flap attached along the third edge of the first wall and the second reinforcing flap attached along the fourth edge of the first wall, and first and second end-closure flaps, the first end-closure flap attached along the third edge of the second wall and the second end-closure flap attached along the fourth edge of the second wall. The first end-closure flap overlaps the first reinforcing flap, and the second end-closure flap overlaps the second reinforcing flap. A method of using the mailing product is also included.

This application is a continuation of U.S. patent application Ser. No. 10/434,694, filed May 9, 2003, which is hereby incorporated by reference in its entirety.

BACKGROUND

Many private commercial overnight couriers (e.g., United Parcel System and Federal Express) are presently able to track the movement of an item through their transport system. Even before the item is delivered to the courier, an employee of the sender can associate a tracking number with the item. After the item is delivered to the courier, the courier system can, in most instances, provide information regarding the location of the item within the transport system to the recipient or sender using the tracking number. In some instances, the courier can also provide information regarding the specifics of the delivery of the item to the recipient (who signed for the package, when they signed for the package, etc.). Businesses have come to rely on this level of accountability provided by the overnight couriers to ensure customer satisfaction, and in turn customer loyalty.

However, this accountability comes at a price. The cost of sending an item by using a private commercial courier is quite expensive when compared, for example, to the costs of the United States Postal Service. The costs of sending an item using a private commercial courier may be orders of magnitude greater than sending the same item using the United States Postal Service.

In response to the growing desire of business to achieve this level of accountability at a reduced price, the United States Postal Service has recently introduced a new postal class that will permit business to request information on the shipment of an item deposited with the United States Postal Service as that item is transported through the federal postal system. At the present time, this new postal rate class requires that the package and contents weigh no more than 13 ounces and that the contents must be in a box, if the package is less than ¾ of an inch thick. Furthermore, the contents must be prepared in a strong and rigid fiberboard container. The parcel must be able to retain its shape, integrity and rigidity throughout processing and handling without collapsing into a letter-size or flat-size parcel. If the package meets these requirements, the Postal Service has indicated that the item will be permitted to use the new postal class.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a mailing product;

FIG. 2 is a plan view of a blank used to make the mailing product of FIG. 1; and

FIG. 3 is a partial cross-sectional view of the mailing product of FIG. 1.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

Although the following text sets forth a detailed description of numerous different embodiments of the invention, it should be understood that the legal scope of the invention is defined by the words of the claims set forth at the end of this patent. The detailed description is to be construed as exemplary only and does not describe every possible embodiment of the invention since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims defining the invention.

It should also be understood that, unless a term is expressly defined in this patent using the sentence “As used herein, the term ‘______’ is hereby defined to mean . . . ” or a similar sentence, there is no intent to limit the meaning of that term, either expressly or by implication, beyond its plain or ordinary meaning, and such term should not be interpreted to be limited in scope based on any statement made in any section of this patent (other than the language of the claims). To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning. Finally, unless a claim element is defined by reciting the word “means” and a function without the recital of any structure, it is not intended that the scope of any claim element be interpreted based on the application of 35 U.S.C. § 112, sixth paragraph.

FIG. 1 shows a light-weight, one-piece mailing product 20. While FIG. 1 shows the mailing product 20 as assembled, FIG. 2 shows the blank 22 from which the mailing product 20 may be assembled. Reference will be made to both FIGS. 1 and 2 in the following discussion of the features of the mailing product 20, as well as FIG. 3.

As seen in FIG. 1, the mailing product 20 may have first and second walls 24, 26. The walls 24, 26 may be parallel to each other, and may be rectangular in shape. As seen in FIG. 2, the wall 24 may have first, second, third and fourth edges 28, 30, 32, 34, and the wall 26 may similarly have first, second, third and fourth edges 36, 38, 40, 42. A third wall 44 may be attached along the first edges 28, 36 of the first and second walls 24, 26, connecting the first wall 24 to the second wall 26. In particular, the interface between the first and second walls 24, 26 and the third wall 44 may occur along fold lines 46, 48, which shall be explained in greater detail below.

As may be best seen in FIG. 2, the mailing product 20 may also include first and second wall flaps 50, 52, the first wall flap 50 attached along the second edge 30 of the first wall 24 and the second wall flap 52 attached along the second edge 38 of the second wall 26. Here as well, the interface between the first wall flap 50 and the first wall 24 and between the second wall flap 52 and the second wall 26 may define fold lines 54, 56. As shown in FIG. 1, and especially in FIG. 3, the first and second wall flaps 50, 52 may be folded along the fold lines 54, 56 so that the first wall flap 50 may substantially overlap the second wall flap 52 with the first and second wall flaps 50, 52 parallel to the third wall 44. The first and second wall flaps 50, 52 may be attached together with an adhesive.

The mailing product 20 may further include first and second reinforcing flaps 58, 60. The first reinforcing flap 58 may be attached along the third edge 32 of the first wall 24, and the second reinforcing flap 60 may be attached along the fourth edge 34 of the first wall 24. The interface between the first reinforcing flap 58 and the first wall 24 may define a first fold line 62, while the interface between the second reinforcing flap 60 and the first wall 24 may define a second fold line 64.

The mailing product 20 may additionally include first and second end-closure flaps 66, 68. The first end-closure flap 66 may be attached along the third edge 40 of the second wall 26, and the second end-closure flap 68 may be attached along the fourth edge 42 of the second wall 26. The interface between the first end-closure flap 66 and the second wall 26 may define a fold line 70, and the interface between the second end-closure flap 68 and the second wall 26 may define a fold line 72.

In regard to the foregoing, it will be recognized that although the first reinforcing flap 58 may be attached along the third edge 32 of the first wall 24, the second reinforcing flap 60 may be attached along the fourth edge 34 of the first wall 24, the first end-closure flap 66 may be attached along the third edge 40 of the second wall 26, and the second end-closure flap 68 may be attached along the fourth edge 42 of the second wall 26, other arrangements are possible. For example, while the first reinforcing flap 58 may be attached along the third edge 32 of the first wall 24, the second reinforcing flap 60 may be attached along the fourth edge 34 of the second wall 24, the first end-closure flap 66 may be attached along the third edge 40 of the second wall 26, and the second end-closure flap 68 may be attached along the fourth edge 42 of the first wall 26.

The mailing product 20 may be used in a method of sending an item through the postal system in the following exemplary manner.

A user may obtain the mailing product 20, which preferably may be partially assembled with the wall flaps 50, 52 attached one to the other using adhesive, but the product 20 otherwise laying flat (i.e., the first wall 24 and the third wall 44 abutting the second wall 26 and the assembly of wall flaps 50, 52). A force is applied to the walls 24, 26 to move the walls 24, 26 relative to each other, causing the product 20 to achieve a tube-like shape, with folding occurring along lines 46, 48, 54, 56. The walls 24, 26, 44 and the assembly of the wall flaps 50, 52 thus may define a space 73 (see FIG. 3) therebetween, into which an item may be disposed.

The user may then fold the first and second reinforcing flaps 58, 60 along the fold lines 62, 64 towards each other so that the flaps 62, 64 are parallel to each other. The user may also fold the first and second end-closure flaps 58, 60 along the fold lines 70, 72 towards each other so that the flaps 70, 72 overlap the first and second reinforcing flaps 58, 60 and may be parallel to each other. The user may then secure the first and second end-closure flaps 66, 68, and deposit the mailing product with the postal service.

The mailing product 20, thus assembled, may have four walls defining an assembled thickness t (as designated in FIG. 1) of the mailing product 20: the third wall 44, the assembly of the wall flaps 50, 52, the assembly of the first reinforcing and end-closure flaps 58, 66 and the assembly of the second reinforcing and end-closure flaps 60, 68. It is believed that the presence of three walls formed by the assembly of overlapping structures may limit the reduction of the thickness of the mailing product 20 substantially from its assembled thickness t. It is believed that the foregoing may be true even through the material that is used to make the mailing product is a non-corrugated material or other material lacking an internal or external rigidifying structure like that found in corrugated material. In this manner, a light-weight material, for example a 18 or 20 point fiberboard material (a fiberboard material having a thickness of approximately 18 or 20 thousandths of an inch), may be used to limit the overall weight of an assembled system, which includes the mailing product 20 and an item disposed therein. It is also believe that the use of the mailing product 20 with an item that would not otherwise qualify for preferential mailing treatment by the United States Postal Service (an item having a thickness less than that specified by the Postal Service; e.g., an envelope or letter) may result in an assembly that permits the sender to take advantage of preferential mailing treatment by the Postal Service, provided the thickness of the mailing product 20 meets or exceeds the thickness limitations set by the Postal Service.

Some of the various other aspects of the mailing product 20, and alternatives therefor, may now be discussed.

Although there are many possible methods and structures that may be used to secure the end-closure flaps 66, 68, an example of one such structure and method is shown in FIGS. 1-3. In particular, the first and second end-closure flaps 66, 68 each may have a first section 74, 76 that substantially overlaps one of the first and second reinforcing flaps 58, 60 when the mailing product 20 is assembled for shipment. Also, the first and second end-closure flaps 66, 68 may have a second section 78, 80 that overlaps a portion 82, 84 of the first wall 24, the portions 82, 84 defining attachment sites. The section sections 78, 80 of the end-closure flaps 66, 68 may have an adhesive applied thereon to be used to attach the end-closure flaps 66, 68 to the first wall 24; while many such adhesives may be used, an adhesive layer with a peelable protective strip that limits contact with the adhesive layer may be preferred.

To facilitate opening of the mailing product 20, at least one of the first and second end-closure flaps 66, 68 (as shown, the flap 66) may have a break-away section 86 between the first section 74 of the end-closure flap 66 and portion of the second section 78 that attaches to the attachment site at section 82. The removal of the break-away section 86 may separate the first and second sections 74, 78 of the end-closure flap 66. Tabs 88 may be attached to the ends of the break-away section 86 to facilitate its removal. It will be recognized that the break-away section 86 is only an exemplary illustration of an opening mechanism to be used with the mailing product 20; the mailing product 20 may be used either with or without the break-away section 86, and may be used with or without an opening mechanism.

As may be further seen with reference to FIG. 2, the mailing product 20 may also include first, second, third and fourth tabs 90, 92, 94, 96. The first and second tabs 90, 92 may be attached to one of the wall flaps 50, 52 (as shown, the flap 52) and the third and fourth tabs 94, 96 may be attached to the third wall 44. During assembly, the flaps 90, 92, 94, 96 may be folded along fold lines 98, 100, 102, 104 so that the first and second tabs 90, 92 are facing and parallel, and the third and fourth tabs 94, 96 are facing and parallel. The first reinforcing and end-closure flaps 58, 66 may then be folded to overlap the first and third tabs 90, 94, and the second reinforcing and end-closure flaps 60, 68 may be folded to overlap the second and fourth tabs 92, 96. 

1. A light-weight mailing product comprising: first and second walls parallel to each other, each wall having first, second, third and fourth edges; a third wall attached along the first edges of the first and second walls connecting the first wall to the second wall; first and second wall flaps, the first wall flap attached along the second edge of the first wall and the second wall flap attached along the second edge of the second wall, the first wall flap substantially overlapping the second wall flap with the first and second wall flaps parallel to the third wall, the first and second wall flaps attached together with an adhesive; first and second reinforcing flaps, the first reinforcing flap attached along the third edge of the first wall and the second reinforcing flap attached along the fourth edge of the first wall; and first and second end-closure flaps, the first end-closure flap attached along the third edge of the second wall and the second end-closure flap attached along the fourth edge of the second wall, the first end-closure flap overlapping the first reinforcing flap and the second end-closure flap overlapping the second reinforcing flap.
 2. The mailing product according to claim 1, wherein the first, second, and third walls, first and second wall flaps, first and second reinforcing flaps, and first and second end-closure flaps are formed from a single piece.
 3. The mailing product according to claim 2, wherein the product is formed from a fiberboard material having a thickness of approximately 20 thousandths of an inch.
 4. The mailing product according to claim 1, wherein each of the first and second end-closure flaps has a first section that substantially overlaps one of the first and second reinforcing flaps and a second section that overlaps a portion of the first wall.
 5. The mailing product according to claim 4, wherein the second section of each of the first and second end-closure flaps is attached to the first wall at an attachment site.
 6. The mailing product according to claim 5, wherein one of the first and second end-closure flaps has a break-away section between the first section of the respective end-closure flap and the attachment site, the removal of the break-away section separating the first and second sections of the respective end-closure flap.
 7. The mailing product according to claim 6, wherein the break-away section has a tab attached thereto.
 8. The mailing product according to claim 6, wherein the second section of the first and second end-closure flaps has an adhesive applied thereto.
 9. The mailing product according to claim 1, comprising: first, second, third and fourth tabs, the first and second tabs attached to one of the wall flaps and the third and fourth tabs attached to the third wall, the first end-closure and reinforcing flaps overlapping the first and third tabs and the second end-closure and reinforcing flaps overlapping the second and fourth tabs.
 10. A method of sending an item, the method comprising: obtaining a light-weight, one-piece mailing product comprising first and second walls parallel to each other, each wall having first, second, third and fourth edges; a third wall attached along the first edges of the first and second walls connecting the first wall to the second wall; first and second wall flaps, the first wall flap attached along the second edge of the first wall and the second wall flap attached along the second edge of the second wall, the first wall flap substantially overlapping the second wall flap with the first and second wall flaps parallel to the third wall, the first and second wall flaps attached together with an adhesive to define a space; first and second reinforcing flaps, the first reinforcing flap attached along the third edge of the first wall and the second reinforcing flap attached along the fourth edge of the first wall; and first and second end-closure flaps, the first end-closure flap attached along the third edge of the second wall and the second end-closure flap attached along the fourth edge of the first wall disposing an item within the space; folding the first and second reinforcing flaps towards each other so that the flaps are parallel to each other; folding the first and second end-closure flaps towards each other so that the flaps overlap the first and second reinforcing flaps and are parallel to each other; securing the first and second end closure flaps; and depositing the mailing product with the postal service. 